Another cracked subframe thread

[rec_rider]

I recently bought an 06 (about 3 months ago) and have been using it for my daily commute as well as short weekend rides. It wasn't pristine by any stretch as it had been dropped on both sides. I decided to remove the plastic and get it painted. During the removal I noticed that the grab handle support was cracked. I have a Shad SH48 case on it and figured this caused the issue. When I removed the plastic I then noticed that the subframe was cracked. The worst part about this was my wife sometime rides on the back and now I know it was extremely dangerous for her to lean back. I'm guessing the issue was there when I bought the bike. Here are the cracks.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130227_203948_223.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130227_203948_223.jpg" border="0" alt=" photo IMG_20130227_203948_223.jpg"/></a>

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130227_203955_785.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130227_203955_785.jpg" border="0" alt=" photo IMG_20130227_203955_785.jpg"/></a>

To fix it I removed the subframe and cut a couple of pieces of 1/8 plate to fit inside the weakened area. I knew that the plate had to be flush with the bottom of the subframe so I ground out a little of the ribs on the underside so the plate would be recessed.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130227_204131_022.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130227_204131_022.jpg" border="0" alt=" photo IMG_20130227_204131_022.jpg"/></a>

The plate on the left has not been ground down yet.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130227_204107_276.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130227_204107_276.jpg" border="0" alt=" photo IMG_20130227_204107_276.jpg"/></a>

I also made a couple of pieces to strengthen the mounting area. I had it welded at a local shop for $40 and I think it turned out ok.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130305_171448_440.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130305_171448_440.jpg" border="0" alt=" photo IMG_20130305_171448_440.jpg"/></a>

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130305_171609_912.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130305_171609_912.jpg" border="0" alt=" photo IMG_20130305_171609_912.jpg"/></a>

Since the major issue is with the Shad case I new I had to create a better solution for the mount. I ditched the stock grab handle and decided to create my own.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130303_190125_690.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130303_190125_690.jpg" border="0" alt=" photo IMG_20130303_190125_690.jpg"/></a>

You can see the broken mount on the stock grab handle part.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130303_190250_002.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130303_190250_002.jpg" border="0" alt=" photo IMG_20130303_190250_002.jpg"/></a>

Here are the two mounted without the plastic (still getting painted) and without the spacers between the subframe and mount.

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130305_192258_750.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130305_192258_750.jpg" border="0" alt=" photo IMG_20130305_192258_750.jpg"/></a>

<a href="https://s239.beta.photobucket.com/user/rec_rider/media/IMG_20130305_192338_169.jpg.html" target="_blank"><img src="https://i239.photobucket.com/albums/ff56/rec_rider/IMG_20130305_192338_169.jpg" border="0" alt=" photo IMG_20130305_192338_169.jpg"/></a>

I should have made a change to the grab handles on my mount but overall I think it'll be much safer when my wife is on the back. This is my first post beyond the introduction and sorry for it being so long. Without the use of this forum I don't think I would have created the mount the way I did. Do you guys have any concerns about how I fixed these issues?

 

[rec_rider]

Sorry guys, it looks like I used the wrong link type for the pics

 

[garauld]

it looks like I used the wrong link type for the pics

well, why not go back and edit them...

 

[HotRodZilla]

It's too bad that after the "upgrade" this forum is such a pain in the ass to use. Quote function doesn't work correctly, it drags on random intervals and most can't post a goddamned photo. I for one will prolly never put another photo of anything on here. Its ridiculous.

 

[RiderX]

it looks like I used the wrong link type for the pics

well, why not go back and edit them...

I think because past the first hour, only Members++ have such abilities.

 

[yamafitter]

I recently bought an 06 (about 3 months ago) and have been using it for my daily commute as well as short weekend rides. It wasn't pristine by any stretch as it had been dropped on both sides. I decided to remove the plastic and get it painted. During the removal I noticed that the grab handle support was cracked. I have a Shad SH48 case on it and figured this caused the issue. When I removed the plastic I then noticed that the subframe was cracked. The worst part about this was my wife sometime rides on the back and now I know it was extremely dangerous for her to lean back. I'm guessing the issue was there when I bought the bike. Here are the cracks.

To fix it I removed the subframe and cut a couple of pieces of 1/8 plate to fit inside the weakened area. I knew that the plate had to be flush with the bottom of the subframe so I ground out a little of the ribs on the underside so the plate would be recessed.


The plate on the left has not been ground down yet.

I also made a couple of pieces to strengthen the mounting area. I had it welded at a local shop for $40 and I think it turned out ok.

Since the major issue is with the Shad case I new I had to create a better solution for the mount. I ditched the stock grab handle and decided to create my own.

You can see the broken mount on the stock grab handle part.

Here are the two mounted without the plastic (still getting painted) and without the spacers between the subframe and mount.

I should have made a change to the grab handles on my mount but overall I think it'll be much safer when my wife is on the back. This is my first post beyond the introduction and sorry for it being so long. Without the use of this forum I don't think I would have created the mount the way I did. Do you guys have any concerns about how I fixed these issues?

I added the photos for the OP to make it read better. For future reference for the Noobs, when copying the photo link into the pop box box for images (if you do it that way) check that the link ends with a .jpg or similar image html tag.

 

[TomInPA]

I posted a photo assist but Yamafitter beat me to it: Next time just use the direct link and the Insert Image function.

Nice job and looks like you got it all worked out.

 

[RossKean]

Looks like a most-excellent subframe repair! Much better than original.

 

[kman09]

WOW, nice work on fixing/modifying your problem.

To bad it had to happen in the first place.

 

[Fred W]

+1 - Very nice work on both the repair and the new rack frame. Looks better than a Givi, but along the same principle.

So... is this the first 2nd gen with the dreaded sub-frame crack? I guess we can't say it only happens on 1st gens anymore.

 

[Mihalis fjr]

Great work!!

I believe you will haven't any problem again!!

 

[rec_rider]

Thanks Yamafitter for fixing my pics. I'll make sure to post properly next time.

I've seen other postings with cracks on their Gen II's. One of them added 1/4" plate to the underside of the subframe all the way to the where the grip handles are connected. It caused a lot of fit issues. I took that to heart and went with something a bit more cautious.

 

[Nikk]

I'm love'n that hand rail replacement. Very nice!

 

[rec_rider]

I'll try this again. I should have designed the handles a little differently to give a bit more room but I think it'll work ok.

 

[huron52]

It's too bad that after the "upgrade" this forum is such a pain in the ass to use. Quote function doesn't work correctly, it drags on random intervals and most can't post a goddamned photo. I for one will prolly never put another photo of anything on here. Its ridiculous.

I can't believe I am agreeing with AJ...

... I fear the end is near! I have totally given up on trying to post pictures as well.

 

[dcarver]

So... is this the first 2nd gen with the dreaded sub-frame crack? I guess we can't say it only happens on 1st gens anymore.

Here is my weld job-

https://candybuttorg.ipage.com/cba/node/247

 

[JamesK]

Sorry guys, it looks like I used the wrong link type for the pics

Nice job on subframe repair.

You might consider making more of those topbox mounts/hand rails. I'd buy this one before the the Givi one if there was an option...

 

[escapefjrtist]

I'll try this again. I should have designed the handles a little differently to give a bit more room but I think it'll work ok.

Top box rack looks great. Nice job!

Start production and I bet you'll sell quite a few.

--G

 

[rec_rider]

It's a thought. I'd have to get this fully tested to make sure it works well but you never know